US20060185975A1 - Decomposition unit - Google Patents

Abstract

A decomposition unit that comprises a plurality of decomposition cells that comprise two metal plates in parallel spaced relation wherein each plate has a layer of molten dielectric material sprayed thereon by using a plasma spray process. Each decomposition cell also has a high voltage high frequency source attached to a metal plate to cause a discharge in the space created between the layers of dielectric material called a discharge area. The plurality of decomposition cells are then placed adjacent to one another and are connected with an insulating material to form a honeycomb configuration of cells.

Description

CROSS REFERENCE TO RELATED APPLICATION
• This application is a non-provisional application gaining priority from provisional patent application Ser. No. 60/655,972 filed Feb. 22, 2005. That provisional is incorporated herein.
BACKGROUND OF THE INVENTION
• This application relates to a device that will decompose pollutants. More specifically this invention relates to a decomposition unit for use in factory smoke stacks.
• Currently, in the art of batteries, such as car batteries, a battery has a cell with one plate made of lead and another plate made of leaded dioxide and has a strong sulfuric acid electrite in which the plates are immersed. From this chemical reaction within the lead acid battery, electrons flow powering whatever device is connected to the battery. Though current lead acid batteries effectively power devices such as automobiles, many problems in the art remain. First, the life expectancy of an average battery in an automobile can be as little as three to four years. Additionally, current car batteries cause inefficiencies within the car motor thus lowering the miles per gallon of gasoline that a car may travel.
• Batteries having a nuclear core have been developed to attempt to harness the energy from a long lasting source. The radioactive materials of these batteries have been used with chemicals known as phosphors to create light that can be converted into electricity. Though electricity has been created, because of the radioactive nature of the core material, these batteries are unsafe for everyday use.
• Attempts to solve the problem of creating an nuclear-cored battery that is safe for everyday use have been made, however scientist have been unable to find a material that will effectively shield the radioactive radiation of the nuclear core material and yet still produce sufficient light that can be efficiently converted into electricity. Thus, there is a need in the art for an improved nuclear battery.
• High temperature ceramics such as Al₂O₃, alumina and zirconium oxide in the past have been used to contain radioactive wastes such that these ceramic containers or sarcophaguses have radioactive waste material placed therein and are buried in the ground. A high temperature ceramic is defined as any ceramic material that has a melting point above 2,000 degrees Centigrade. The ceramic structure is stable and dense enough that this structure is not altered by the radioactive radiation. Nonetheless, high temperature ceramics have never been used in the field of nuclear-cored batteries because the dense structure of the ceramics is not conducive to the production of photons using a radioactive source.
• Additionally, in the current art of manufacturing processes that have been developed to produce similar crystals to those that will be created in manufacturing the nuclear-cored battery are not conducive to the mass production needed to make a profit in the business community. Specifically, during the production of photoluminescent crystals the manufacturing process requires multiple steps of mixing, milling, and heating material continually. These processes not only take a lot of time and effort, but also produce inferior crystals. Thus, there is a need for a new method of manufacturing crystals that reduces the cost to produce the crystals while increasing the quality of the crystal.
• Furthermore, to assist in the manufacturing process of the nuclear-cored battery the current manufacturing equipment that would be used to manufacture the battery cause inefficiencies during the manufacturing process. Specifically, a problem exists with the nano-material production equipment, such as a plasma spray gun that will be used to manufacture the nuclear-cored battery of this disclosure. A problem with current plasma spray guns exists in that these guns use a tungsten anode and electrode that deplete into the plasma stream as the equipment is used, thus limiting the life of the anode and electrode such that current anode and electrodes within a plasma spray gun only last approximately 250 hours. Thus there is a need in the art to improve upon the life of the anode and electrode with a plasma spray gun.
• Another technology that may be improved uses a similar solution as will be disclosed regarding the nano-material production equipment and this technology is known as a fuel saver. A fuel saver converts O₂into O₃. Currently, alumina plates are placed on top of copper plates thus creating the fuel saver and the combination of these plates are used as discharge plates within the fuel saver. Nonetheless, these fuel saver units known in the art do not yield an optimum output potential. Thus, there is a need for an improved manufacturing process to create a fuel saver, and a need for a more efficient fuel saver.
• A fuel saver is one example of a decomposition cell. Decomposition cells are used in manufacturing facilities to be placed in smoke stacks to decompose pollutants into chemicals that are not harmful to the environment. Specifically, there is a need for an improved decomposition cell that will more efficiently decompose pollutants to create waste materials that are safe for the environment.
• Thus, the principal object of the present invention is to use a plurality of decomposition cells to create a decomposition unit that will efficiently decompose pollutants.
• Another object of the present invention is to increase the surface area of a decomposition unit to more efficiently decompose pollutants.
• Another object of the present invention is to use a thermal plasma spray process to improve upon a decomposition cell.
• Yet another object of the present invention is to improve the dielectric quality of a decomposition cell.
• These and other objects, features, or advantages will become apparent from the specification and the claims.
BRIEF SUMMARY OF THE INVENTION
• A decomposition unit that comprises a plurality of decomposition cells that comprise two metal plates in parallel spaced relation wherein each plate has a layer of molten dielectric material sprayed thereon by using a plasma spray process. Each decomposition cell also has a high voltage high frequency source attached to a metal plate to cause a discharge in the space created between the layers of dielectric material called a discharge area. The plurality of decomposition cells are then placed adjacent to one another and are connected with an insulating material to form a honeycomb configuration of cells.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a sectional view of a nuclear-cored battery;
• FIG. 2 is a cut away plan view of a sphere of an nuclear-cored battery;
• FIG. 3 is a sectional view of a super magnet;
• FIG. 4 is a flow diagram of a manufacturing process of a nuclear-cored battery;
• FIG. 5 is a schematic diagram of the equipment used during the manufacturing process of a nuclear cored battery;
• FIG. 6 is a flow diagram of a manufacturing process of a nuclear-cored battery;
• FIG. 7 is a plan side view of one embodiment of a disposable battery using a layered nuclear-cored battery;
• FIG. 8 is a cut away plan side view of one embodiment of a disposable battery using a layered nuclear-cored battery;
• FIG. 9 is a sectional view of a plasma spray gun;
• FIG. 10 is a flow diagram of a recycling process of an nuclear-cored battery;
• FIG. 11 is a side plan cut away view of a plasma spray system;
• FIG. 12 is a sectional view of a decomposition cell;
• FIG. 13 is a sectional view of a decomposition unit; and
• FIG. 14 is a sectional view of a fuel saver.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
• FIG. 1 shows an atomic battery or nuclear-coredbattery10. Nuclear-coredbattery10 is created by producing a plurality of energy sources in the form of spheres12 (FIG. 2) that each have anuclear core14 that emits alpha, beta, or gamma radiation.Nuclear core14 is comprised of any radioactive material including, uranium, uranium carbonate, uranium oxide, strontium, and strontium oxide.
• Thenuclear core14 is surrounded by aceramic phosphor material16 that is in one embodiment a crystalline having a carbon defect such that theceramic phosphor material16 in combination with the nuclear core forms a lightdissipating material17. In one embodiment, the ceramic phosphor material comprises a high temperature ceramic. In another embodiment this high temperature ceramic comprises a matrix having Al2O3:C. In yet another embodiment zinc sulfide, or another high temperature ceramic having a carbon defect is used. The ceramic material within theceramic phosphor material16 is used to shield and absorb the radiation emitted by thenuclear core14 while the phosphors are excited by the radioactive radiation of thenuclear core14 causing the phosphors to produce energy in the form of photons. In another embodiment lanthides are used as a defect for the phosphors. The carbon defect increases the bandwidth of the ceramic material, and the lanthides are used to increase the bandwidth of the phosphors. Thus, the ceramic material prevents radiation from being emitted past theceramic phosphor material16, yet thismaterial16 is still able to produce photons.
• In one embodiment theceramic phosphor material16 is made into a crystalline (crystal) that is an amorphous crystalline or a structured crystalline and that is manipulated during the manufacturing process so that the photons being emitted by thematerial16 are at an optimum wavelength (and thus color) to maximize the efficiency of the nuclear-coredbattery10. One example of how the crystalline is manipulated is by adding MO.m(Al2O3):Eu,R to the ceramic phosphor material, wherein M is chosen from one of the alkaline metals such as strontium, calcium, and barium; R is any of the lanthanides; Eu is present at a level from about 0.05% to about 10% by weight and preferably 0.1-5% by weight; and R is present at a level from about 0.05% to about 10% by weight and preferably 0.1-5% by weight. Thus the final formula of the ceramic phosphor material will comprise the matrix MO.m(Al2O3):C:Eu,R.
• Another example of a material that is added to theceramic phosphor material16 to manipulate the output frequency of the photons being emitted is yttrium oxysulfide doped with titanium and magnesium material that forms a crystal that emits red to orange wavelengths of light. Thus for red and orange wavelengths the ceramic phosphor material comprises the matrix MOS:Mg,Ti,Eu wherein M is chosen from a group consisting of MgO, ZnO, ZrO, CuO, Yttrium Oxide, or Gallium Oxide.
• The excitation of the base light emitter, such as Al2O3:C, causes the stimulation of the crystals and the combined frequency gives the final output color. Thus the output frequency of theceramic phosphor material16 is manipulated to any color in the visible spectrum. Below is a list of examples of different ceramic phosphors and the color wavelengths of the photons that are emitted by each depending on the amount of each element provided:
• • 1. Green—A polycrystalline structure of Alumina incepted with carbon and mixed with a matrix of Europium Oxide, Strontium Carbonate, also Dysprosium Oxide.
  • 2. Blue—A polycrystalline structure of Alumina incepted with carbon and mixed with a matrix of Europium Oxide, Strontium Carbonate, also Dysprosium Oxide.
  • 3. Yellow—A polycrystalline structure of Alumina incepted with carbon and mixed with a matrix of Europium Oxide, Strontium Carbonate, Barium Carbonate, also Dysprosium Oxide.
  • 4. Orange—A polycrystalline structure of Alumina incepted with carbon and mixed with a matrix of Europium Oxide, Strontium Carbonate, also Dysprosium Oxide. Mixed with a polycrystalline structure of Yttrium Oxysulfide and mixed with a matrix of Europium Oxide.
  • 5. Red—A polycrystalline structure of Yttrium Oxysulfide and mixed with a matrix of Europium Oxide, also Magnesium Titanium.
  • 6. White—A polycrystalline structure of Alumina incepted with carbon and mixed with a matrix of Europium Oxide, Strontium Carbonate, Neodymium Oxide, also Dysprosium Oxide.
  • 7. Violet—A polycrystalline structure mixed with a matrix of Europium Oxide, Calcium carbonate, also Neodymium Oxide.
• Thus, each combination listed creates a separate crystalline structure depending upon the content of each element present. Each crystalline separately is unique in its interaction with different radiations produced by thenuclear core14, and each will produce a different wavelength of visible light emitted from the crystalline.
• Surrounding theceramic phosphor material16 is aphotovoltaic layer18 that transforms the photons into a flow of electrons to create an energy source, orsphere12. One will appreciate that in one embodiment thephotovoltaic layer18 is made of an amorphous silicon that also is altered with defects by, for example, doping the material with magnesium in order to manipulate a stimulating frequency of thephotovoltaic layer18. Other examples of defects include titanium and chromium. Thus the output frequency of the photons generated by theceramic phosphor material16 is manipulated or tuned while manipulating or tuning the stimulating frequency of thephotovoltaic layer18 so that the most efficient amount of light created by theceramic phosphor material16 is converted into an electron flow by thephotovoltaic layer18.
• After a plurality ofspheres12 are created the battery is formed by surrounding a plurality ofspheres12 with aconductive material20 that is an intermediate layer that carries thespheres12. Thisconductive material20 comes into direct contact with thespheres12 and in one embodiment is a conductive polymer, one example of which is a sulfidized polymer. One such conductive polymer is poly(3,4-ethylenedioxythiophene) polystyrenesulfonate. A P andN layer22 comprising a P layer22aand an N layer22bsandwiches the spheres therebetween to harness the electron flow created by thephotovoltaic layer18 to create the nuclear-coredbattery10. Additionally, a layer of insulatingmaterial23 can be used to surround the P andN layer22.
• Finally,spheres12 in one embodiment are in powder form and will range in size from 50 microns to sub micron in size depending on the application and output. Nonetheless, in another embodiment a metal is added to thenuclear core14 of thebattery10 in order to increase the size of thespheres12 for macro-sized applications.
• As shown inFIG. 3, in an alternative embodiment amagnetic material24 is placed around the plurality ofspheres12 to create asuper magnet26. Specifically, the flow of electrons created by thephotovoltaic layer18 interacts with themagnetic material24 to magnetize theouter surface28 of themagnetic material24.
• In operation, thenuclear core14 emits radiation, for example, beta radiation that is an electron. When the electron comes in contact with theceramic phosphor material16 the radioactive radiation is stopped by the ceramic, yet the electron excites the phosphors causing an electron to “jump” from a4d valence energy level to a higher valence energy level within a phosphor. When that electron “settles” back to its original4d state, energy in the form of a photon is emitted. When theceramic phosphor material16 includes a carbon defect in its matrix the carbon defect increases the bandwidth of the phosphor allowing more photons to be generated. Furthermore, the matrix of theceramic phosphor material16 will determine the frequency of the photon that is being emitted from theceramic phosphor material16. These photons are then absorbed by thephotovoltaic layer18 to create an electron flow that is harnessed by the P andN layer22 to cause thebattery10 to function.
• When other radioactive radiations are present such as gamma and alpha radiation, the phosphors still become “excited” and produce photons, but not in the same way as beta radiation. Thus all types of radioactive material may be used as thenuclear core14.
• Manufacturing the nuclear-cored battery involves a multi-step process.FIG. 4 shows a flow chart of the multi step process used during the manufacturing of the battery andFIG. 5 shows a schematic diagram of the equipment used during this process. Processing the nuclear material is thefirst step30. This is preformed in a multitude of ways depending on the initial source. If the nuclear material is of a mixed matrix of different radiation sources division is made by dissolving the materials with the mixed matrix and separating these materials via gravimetric. The weight and density of the different materials in the mixed matrix causes these materials to separate into layers making it possible to divide materials as needed.
• Thenext step32 is to process the nuclear material via aspray dryer34 into a spherical metal or compound to be used as thenuclear core14. The core14 in one embodiment is a compound that is an oxide or carbonate that creates a stronger structure, with a higher melting point than the metal that the oxide or carbonate are derived from. Other methods and equipment such as a precipitation method or some other form of sprayer is also used to create thenuclear core14.
• At step36 a ceramic phosphor slurry material that in one embodiment is made of a base material of Al2O3:C and phosphors is created. The ceramic phosphor slurry is a frequency alternating mixture that in one embodiment comprises strontium carbonate, europium oxide, dysprosium oxide, or the like (depending on the output frequency desired) that is mixed into a water and alumina powder. The ceramic phosphor slurry, water and alumina powder are milled together to a nano mean size to form a ceramic phosphor slurry material. This is preformed in a media mill or mixingchamber38 or other systems. In one embodiment a carbon defect is added to the ceramic phosphor slurry material by using graphite, or another carbon additive while making the ceramic phosphor slurry.
• Atstep40 the nuclear core material is introduced to the ceramic phosphor slurry material and then at step42 a temporary binder is added (ammonia nitrate or another gas is used to create a porous structure as necessary) and the ceramic phosphor slurry material with a nuclear core material having a temporary binder is then mixed to create a homogenous mixture. Examples of the temporary binding material are methal cellulose, poly vinyl alcohol, or the like.
• This homogenous mixture is processed again through the spray drier34 to dry the homogenous mixture to form an outer shell at step46. At step46 the homogenous mixture is delivered to the spray drier34 and into the cavity of the spray drier34 by double annulus spray nozzle or discharge wheel. The homogenous mixture is then hit with a blast of hot air that evaporates the water within the homogenous mixture and dries the temporary binding material atstep48 to form a temporarily bound layer of mixed ceramics. Atmospheric gas of nitrogen, argon, and/or carbon dioxide is used to assist in the process. In the embodiment wherein the base ceramic is Al2O3:C step48 forms a semi ridged spherical particle with thenuclear core14 surrounded by a temporarily bound layer of mixed ceramics having an alumina structure.
• Atstep50 the particle created atstep48 is subjected to a high temperature portion of the processing, or plasma thermal process using a thermalplasma spray system52 having at least oneplasma gun53. With temperatures that are adjusted from 2,000 to over 15,000 centigrade the mixed ceramics fromstep48 are brought to a molten state for a short amount of time, preferably under a minute, thus creating a layer of mixed ceramics in a molten state. While in this molten state the temporary binding material will burn out and the nuclear core with the layer of mixed ceramics becomes an amorphous structure as a result. The plasma stream sinters the layer of mixed ceramics to densify and calcinate or purify the layer. In one embodiment the layer of mixed ceramics has an alumina structure and this alumina structure is brought to a molten state for a short amount of time creating the amorphous structure.
• While the particle created atstep48 is subjected to the high temperature portion of the processing structural defects are introduced. In one embodiment these defects include carbon defects and/or lanthide defects. Once a carbon defect is added the layer of mixed ceramics in combination with thenuclear core14 becomes alight dissipating material17. Thus, thenuclear core14 after this high temperature processing will no longer be radioactive in nature past the layer of mixed ceramics. The radioactive decay will be transformed into light that is emitted out from thelight dissipating material17.
• During step54 thelight dissipating material17 is propelled into a quenchingchamber56 and a pair of cooling nozzles that in one embodiment emit a crosscurrent of quenching gas that is an air and gas mixture cools and incepts further amounts of carbon into thelight dissipating material17 to form a crystalline. One will also appreciate that the temporary binder provided some carbon content as it burned out but the use of carbon dioxide in the quenching gas will allow for total coverage of carbon within thelight dissipating material17. Also the use of nitrogen, or other inert gas, as a quenching gas will encourage the clarity of the crystalline allowing for a higher transfer of light from thelight dissipating material17. Rather than add the carbon defect instep52, alternatively the carbon defect is added just in step54. The heating of the nuclear core with a layer of mixed ceramics allows the introduction of the carbon defect atstep52, step54, or both. Thelight dissipating material17 now quenched and treated with the chamber gasses is collected by acyclonic chamber58 that is separate from the quenchingchamber56 atstep60. Thelight dissipating material17 is then removed when collected.
• Construction material in the quenchingchamber56 will be similar to that of the spray drier34. Additionally, ascrubber system62 is utilized to prevent the discharge of uncoated nuclear core particles in both the spray dry process and thermal plasma spray stages.
• Once thelight dissipating material17 is created the material is spray dried with a coating of photovoltaic material such as silicon by thespray dryer34 at step64. At step66 this layer is treated again with the thermal plasma process to densify the silicon on thelight dissipating material17 to create thephotovoltaic layer18, thus creating thesphere12. By using the thermal plasma process the photovoltaic layer in one embodiment has an amorphous structure. This layering technique will allow for a high strength and small particle size with each layer interacting with the next. Thespray dryer34 gives thespheres12 their shape and one will understand that these small spherical particles are in one embodiment the form of a powder.
• At step68 the finished powder is sandwiched between organic P and N layers22 to draw away the electrons being discharged from thephotovoltaic layer18 of thespheres12. Leads are connected to the P and N layers22 to transport energy to a source consumer of the electricity at step70. The P and N layers22 in one embodiment are applied as a spray and conform to any shape desired or as a sheet72 (FIGS. 7 and 8) that is later inserted into a commercial product.
• One will appreciate that though this method of manufacturing places aceramic phosphor layer16 over anuclear core14 to form alight dissipating material17, that in another embodiment only the ceramic phosphor slurry undergoes the manufacturing process described to create aceramic phosphor crystalline16. This crystalline16 is then used in association with thenuclear core14 to create alight dissipating material17.
• In another embodiment seen inFIG. 6 the nuclear material is layered with the Al2O3:C first instep74, then processed in high temperature instep76, then recoated with the phosphor instep78, and processed with higher temperatures to alter the output frequency atstep80. The mixing of a matrix of materials is used on low to mid output radioactive materials but high output materials will require the shielding first then the altering of the frequency. This also offers an opportunity to manipulate a carbon inception of an alumina layer. The use of pre-manufactured materials exists to create these layers. Again, a binder is used to hold the layers together temporarily until high temperature processing is implicated.
• The use of a discharge circuit in one embodiment is utilized to remove unused excess electricity created by the nuclear-coredbattery10. This electricity is converted to heat or other forms of energy to dissipate excess capacity. This energy could also be redirected to a capacitor to store the electricity during sporadic and inconsistent use of the source. The reason for the use of this circuit is that thebattery10 is going to give electricity continuously without delay for the duration of the core materials half-lives.
• FIGS. 7 and 8 show embodiments wherein a layeredbattery82 is formed. Specifically, in this embodiment the P and N layers are applied as a spray to form a nuclear coreenergy source sheet72. In this embodiment thesheet72 is rolled or coiled into a cylinder and inserted into a plastic or metal housing orcase84 having a first and second ends86 and88.FIG. 7 shows thecoiled sheet72 outside thecase84 and tapered; however, in use the sheet is coiled and within thecase84. A firstconductive lead90 is electrically connected to the P layer22aand is attached to thefirst end86 to create ananode92 and similarly a secondconductive lead94 is electrically connected to the N layer22band attached to thesecond end88 to create anelectrode96. One will understand that a layer of insulatingmaterial98 may be attached to thecase84 to insulate thecase84 from thesheet72.
• As shown inFIG. 8, in another embodiment a plurality ofsheets72 are stacked upon or are adjacent to each other within thecase84. In this embodiment thefirst end86 of the case will come into contact with a P layer22aof asheet80 to form theanode92 and thesecond end88 will come into contact with a N layer22bof anothersheet72 to form theelectrode96. In this embodiment, if an insulating layer is desired, conductive leads are used to connect the P layer22ato thefirst end86 ofcase84 and to connect the N layer22bto thesecond end88 ofcase84.
• Other products that can be produced from this source of energy are: room temperature super conductors, super conducting cables/wires, resistance free polymers, infinitely formable power supplies, energy sources for: electronics, houses, cities, countries, automobiles and other forms of transportation.
• When in use the product life, whether a battery, or another product using the energy source disclosed above, is determined by the material(s) of thenuclear core14. Therefore, a manufacturer by selecting the nuclear core material has the ability to pre-select a time limit that a product will function. This is accomplished by first testing nuclear materials by carbon dating or the like to determine a half life for the materials to provide nuclear materials having known half lives. Then a nuclear material having a known half life is selected and used as anuclear core14 of a nuclear-coredbattery10. Thus, once this nuclear core ceases to produce effective radioactive radiation the product will shut down.
• Another way of pre-selecting the time limit of a product that is produced from the above energy source is to attach a timing mechanism such as a timing circuit to the product that will terminate the operation of the product after a pre-selected occurrence. In one embodiment the timing mechanism is programmed to disable a product after a pre-selected period of time such as for example 10 years. In an alternative embodiment the timing mechanism disables a vehicle after a pre-selected amount of distance traveled by the vehicle. For example the timing mechanism could sense when a vehicle has driven 50,000 miles and disable the vehicle at that time.
• The reason for pre-selecting the life of a product using theenergy source12 is because when a radioactive core material is used, this energy source can have the potential of lasting for trillions of years. Thus, without pre-selecting the time of the life of a product, consumers will have no need to repurchase a product. Furthermore, many devices such as DVDs, personal electronics, and others that could use theenergy source12 involve technologies that are continually being improved. Thus, products having a pre-selected life will allow for the miniaturization of many electronics and the development of new technologies to ensure products remain up to date. Thus to ensure technology will continue to move forward, the products using the nuclear-coredbattery energy source12 will need to have a pre-selected product life.
• In an embodiment wherein a product uses a timing circuit to pre-select the time of the life of a nuclear cored product, this product will need to be recycled. The steps for recycling a nuclear-cored battery are shown inFIG. 9. Recycling of the nuclear-cored battery can be accomplished by first milling the battery to break it apart into smaller pieces, as represented instep100. Then the pieces undergo a thermal burn, such as in a kiln to melt way the P and N layer and the photovoltaic layer as shown instep102. Remaining after the thermal burn is thelight dissipating material17 that is either chemically treated with an acid to etch the ceramic within thelight dissipating material17 or physically treated with a circulating wash to remove any residual deposits or impurities on the light dissipating material such as excess carbon, as shown instep104. Thus, thelight dissipating material17 may then be reused in another application as shown instep106.
• FIG. 10 shows an improved thermalplasma spray gun108 that is one example of one embodiment of thermalplasma spray gun53 used during the manufacturing of the nuclear-coredbattery10. Theplasma spray gun108 has ahousing109 with aplasma stream conduit110 that extends from aninlet end112 to adischarge end114 having adischarge aperture116. Within theplasma stream conduit110 is adischarge dielectric anode118 and adischarge dielectric electrode120. In communication with theplasma stream conduit110 aregas feed conduits122 that extend through thehousing109 of theplasma spray gun108 such that a single gas, or mixture of gasses, is exposed to theanode118 andelectrode120 within theplasma stream conduit110 to create a stream of plasma therein.Supply conduits126 extend through theplasma spray gun108 and are in communication with thedischarge end114 of theplasma stream conduit110 to supply powdered metals or ceramics to the plasma stream to create a molten material.
• A voltage supply is electrically connected to theplasma stream conduit110 to supply voltage to theconduit110 to create an electrostatic discharge that will convert feed gases into a plasma stream. This voltage supply may be integrated as a circuit that is part of theplasma gun108 or may be a voltage supply that is remotely located from theplasma gun108
• The use of hydrogen, nitrogen, helium, and/or argon is used to produce the plasma stream. A hydrogen nitrogen combination will generate sufficient heat with the ability not to interact with the structure and alter the nuclear core with a layer of mixed ceramics introduced to theplasma spray gun108. A high-energy electrostatic discharge through the gas causes the plasma phase of the gas to be generated. The gas is then ejected from theplasma stream conduit110 of theplasma spray gun108, and metallic or ceramic powders are introduced into the stream via thesupply conduit126 where the heat is transferred to the powders.
• Theanode118 andelectrode120 create an electrostatic discharge causing the formation of the plasma gas. During this electrostatic discharge high amounts of energy cause a pitting of the surfaces of theanode118 andelectrode120. To solve this problem theanode118 andelectrode120 are milled to remove 2-20 mills and a dielectric material such as alumina is deposited onto theanode118 andelectrode120 surfaces to create adielectric barrier128, preventing the pitting from the discharge of the static field, thus increasing the efficiencies of the unit and allowing for a higher purity in the end product. This dielectric material may be applied to theanode118 and electrode surfaces using a thermal plasma process to spray molten dielectric material onto theanode118 andelectrode120. Furthermore, in one embodiment the dielectric material may be doped with another material, such as for example, magnesium.
• FIG. 11 shows a reconfiguredplasma spray system130 that is an example of one of the embodiments ofplasma spray system60 that is used during the creation of the nuclear-cored battery. Specifically, this embodiment shows a reconfiguredplasma system130 that will more efficiently handle a liquid stream of material thus creating a wider spray area. By using this configuration the spray dry process may be eliminated from the processing.
• Specifically, theplasma spray system130 ofFIG. 11 shows a plurality ofsmaller plasma jets131 that are configured in a 3-12 inch diameter around a centrally locatedjet132 that is a liquid generating device within ahousing133. Thejets131 are one embodiment of thespray gun108 shown inFIG. 10 that generate a plasma stream by utilizing ananode118 andelectrode120 in combination with gases fromgas feed conduits122 within aplasma stream conduit110 having ainlet end112 and dischargeend114. Similarly, the centrally locatedjet132 is also one embodiment of thespray gun108 wherein a material powder, such as metallic powder is fed into thedischarge end114 of theplasma stream conduit110 viasupply conduit126 so that molten, or liquid metal is discharged by theliquid generating device132. In one embodiment the centrally locatedjet132 has a double annulus spray head that generates a stream of atomized liquid.
• The plurality ofplasma spray jets131 are positioned so that their plasma streams will intersect at apoint134 along the path of the atomized liquid and thus become part of the atomized liquid stream. With this system in place a smaller particle is produced and fewer steps are required to produce the same product.
• FIG. 12 shows adecomposition cell136 that functions to cause the decomposition and production of materials in a discharge field. Thedecomposition cells136 are placed in a conduit in order to break pollution down into its simplest components to minimize pollution. For example, in one embodiment, adecomposition cell136 is placed in a smoke stack of a manufacturing facility to convert pollutants into environmental safe oxygen or carbon.
• Thedecomposition cell136 ofFIG. 12 is manufactured by taking afirst metal plate138 such as copper and using aplasma gun53 or108 to spray a molten dielectric material such as alumina onto themetal plate138 to create a firstdielectric layer140. One will appreciate that by using theplasma spray gun53 or108 to spray the molten dielectric material on themetal plate138, an optimum contact area between thedielectric layer140 and theplate138 is achieved to create a moreefficient decomposition cell136. Furthermore, by using theplasma spray gun53 or108, magnesium oxide may be doped into the molten dielectric material such as alumina to further increase the efficiency of thedecomposition cell136. Similarly, the molten dielectric material is then sprayed onto asecond metal plate142 to create asecond dielectric layer144.
• Next theplates138,142 are placed in parallel spaced relation to create adischarge area146 wherein air is able to flow through thecell136. Thus during a discharge process, when the twometal plates138,142 are electrically connected to a high voltagehigh frequency source148 and when voltage is supplied to the twometal plates138,142 anelectrostatic discharge149 occurs in thedischarge area146, thus decomposing pollutants flowing therethrough and filtering the air. One will appreciate that the high voltagehigh frequency source148 may be supplied by a circuit that is part of thedecomposition cell136 or a by a voltage source remote to thecell136.
• As best shown inFIG. 13, a plurality ofdecomposition cells136 are placed together to form adecomposition unit150. Thedecomposition unit150 ofFIG. 13 has a honeycomb configuration ofdecomposition cells136 that extend between first andsecond side walls152,154 thus creating a plurality ofdischarge areas146 that can be separated by an insulatingmaterial156. Because of the plurality ofdischarge areas146 in combination with the honeycomb configuration of theunit150 the surface area of thedischarge area146 within thedecomposition unit150 increases, thus causing more pollutants to be decomposed as the pollutants flow through thedecomposition unit150.
• In one embodiment shown inFIG. 14, thedecomposition cell136 is used primarily to convert O₂to O₃. In this embodiment thedecomposition cell136 is referred to as afuel saver157. Thefuel saver157 specifically is created by taking a rolledcopper body158 and thermally applying analumina matrix160 thereto. One will understand that by thermally applying the alumina to the rolled copper the surface area between the copper and alumina is increased while minimizing the gap between the copper and alumina matrix. Additionally, the alumina is doped with magnesium oxide to change the oxygen state in the final product from an O₃thus yielding a higher output during the discharge process. Because O₃has more chemical bonds than O₂, O₃burns much more intensely than O₂. Thus a fuel saver is used in an engine to convert O₂to O₃within the engine to provide an improved fuel system that creates optimum gas mileage for the engine.
• It will be appreciated by those skilled in the art that other various modifications could be made to the device without the parting from the spirit in scope of this invention. All such modifications and changes fall within the scope of the claims and are intended to be covered thereby.

Claims (8)

1. A decomposition unit comprising:

a plurality of decomposition cells secured between a pair of sidewalls to form a honey comb configuration; and

the decomposition cells having a first metal plate with a first layer of dielectric material in spaced relation to a second metal plate with a second layer of dielectric material.

2. The decomposition unit ofclaim 1 wherein insulating material is disposed between each decomposition cell.

3. The decomposition unit ofclaim 1 wherein the first layer of dielectric material is applied by spraying a molten dielectric material onto the first metal plate.

4. The decomposition unit ofclaim 1 wherein the second layer of dielectric material is applied by spraying a molten dielectric material onto the second metal plate.

5. The decomposition unit ofclaim 1 wherein the dielectric material is doped with magnesium.

6. The decomposition unit ofclaim 1 wherein the decomposition cells further have a high voltage source electrically connected to the first metal plate.

7. A decomposition unit comprising:

a plurality of decomposition cells secured between a pair of sidewalls to form a honey comb configuration;

the decomposition cells having a first metal plate with a first layer of dielectric material in spaced relation to a second metal plate with a second layer of dielectric material; and

wherein the first layer of dielectric material is applied by spraying a molten dielectric material onto the first metal plate.

8. The decomposition unit ofclaim 7 wherein the second layer of dielectric material is applied by spraying a molten dielectric material onto the second metal plate.

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